Additively Manufactured Valve Piston for Low-Pressure-Loss Flow
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Solution Overview
Problem
Conventional valve pistons for directional control valves have complex manufacturing processes, leading to high pressure loss and reduced energy efficiency due to complex assembly and joining steps, as well as suboptimal internal channel designs that result in unfavorable flow conditions.
Innovation Solution
A valve piston with an additively manufactured internal passage that is radially spaced from the central axis, featuring a curved or bulbous shape and variable cross-sections to optimize pressure medium flow, reducing pressure loss and improving flow efficiency by minimizing dead spaces and turbulence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional machining and joining methods are used to manufacture valve pistons with internal channels, then the manufacturing process is complex and time-consuming, but the structural integrity and pressure-tightness can be ensured through testing
Solution Approach 1:
The patent merges multiple manufacturing operations (machining, drilling, joining) into a single additive manufacturing process. The valve piston with complex internal channels is built layer-by-layer in one continuous process, eliminating the need for separate machining steps and assembly operations, thereby reducing manufacturing complexity and cycle time
Solution Approach 2:
The patent changes the manufacturing approach from subtractive (machining) and assembly-based to additive manufacturing. This parameter change enables direct creation of complex geometries including internal channels, eliminating the need for complex tooling and multiple assembly steps, thus improving ease of manufacture and reducing time loss
2Strength
If conventional joining methods are used to assemble valve piston components, then the assembly strength can be achieved, but the joints are subjected to high forces from pressure differential and require extensive testing
Solution Approach 1:
The patent eliminates the need for joining multiple components by manufacturing the entire valve piston as a single integrated part using additive manufacturing. This removes all joints and interfaces that would otherwise be subjected to high pressure forces, inherently ensuring pressure-tightness without requiring extensive testing
Solution Approach 2:
The patent extracts and removes the joining operations and associated test requirements from the manufacturing process. By producing a monolithic structure, the problematic joints and their reliability concerns are completely eliminated, leaving only the additive manufacturing process itself
3Ease of manufacture
If simple central passages are used in additively manufactured valve pistons, then the manufacturing is easier, but the pressure medium flow has dead zones and large-scale turbulence causing high pressure loss
Solution Approach 1:
The patent applies curved and tapered geometries to the internal passages instead of simple straight cylindrical channels. The curved walls and varying cross-sections guide the pressure medium flow more smoothly, reducing dead zones and turbulence, thereby minimizing pressure loss while maintaining additive manufacturing feasibility
Solution Approach 2:
The patent varies the passage geometry locally along its length, with different cross-sectional areas and wall angles at different positions. This local optimization of the flow path ensures smooth transitions and eliminates stagnant zones, improving energy efficiency without complicating the overall additive manufacturing process
Data Source
Figure 1a~1b
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AI summary
A valve piston with a central axis is disclosed, along which spaced-apart control geometries are provided, bypassed by a passage through the valve piston that is at least partially additively manufactured. A valve with a valve housing and a housing recess in which this valve piston is adjustably mounted relative to the valve housing is also disclosed.